datasheet for CD5.241
CD5.241-L1
DC/DC Converter 24V, 3.8A
CD-Series
DC/DC CONVERTER
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24V DC-Input
Isolated 24Vdc Output
NEC Class 2 Output
Quick-connect Spring-clamp Connection Terminals
Efficiency up to 90.5%
Width only 32mm
Full Power Between -25°C and +60°C
Soft-start Function Included
Minimal Inrush Current Surge
Reverse Input Polarity Protection
3 Year Warranty
GENERAL DESCRIPTION
SHORT-FORM DATA
The Dimension CD-Series offer DIN-rail DC/DC converters
in the 92-120W output power range in a very compact
housing. These DC/DC converters are allowed to run
with a battery or similar sources or can also be used to
refresh and stabilize the 24Vdc on the end of long cable
runs. The basic units include all the essential basic
functions while the -S1 version is equipped with quickconnect spring clamp terminals, a DC-OK-contact which
monitors the output and an input-low-relay-contact.
The –L1 version additionally fulfills the NEC Class 2
requirements. All devices except the CD5.241-L1 have a
PowerBoost of 20% incorporated. This extra power can
even be used continuously up to +45°C.
Output voltage
Adjustment range
Output current
Output power
Output ripple
Input voltage
Input voltage range
Input current
Input inrush current
Efficiency
Losses
Temperature range
Derating
Hold-up time
Dimensions
CD-Series
CD5.121
24V->12V
CD5.243
12V->24V
CD5.242
48V->24V
Related products
DC 24V
not adjustable
3.8A
92W
< 50mVpp
DC 24V
14.4 to 32.4Vdc
typ. 4.25A
typ. 1.2A peak
90.5%
9.7W
-25°C to +70°C
0W/°C
typ. 7ms
32x124x102mm
NEC Class 2
20Hz to 20MHz
full specified
at 24Vdc input
at 24Vdc input
at 24Vdc input
operational
+60 to +70°C
at 24Vdc input
WxHxD
24V->24V
CD5.241
SLD2.100
24V->5V
24V->24V, NEC Class 2,
CD5.241-L1 Spring-clamp-terminals,
24V->24V,
CD5.241-S1 Spring-clamp-terminals,
Input-low, DC-OK signals
MARKINGS
ORDER NUMBERS
DC/DC Converter
CD5.241-L1
Standard unit
Accessory
ZM1.WALL
ZM11.SIDE
Wall mount bracket
Side mount bracket
Ind. Cont. Eq.
UL 508, NEC Class 2
Class I Div 2
UL 60950-1
UL 61010-1
ATEX
II 3G Ex nAC II T4
Class I Div 2
EMC, LVD
Oct 2009 / Rev. 1.0 DS-CD5.241-L1-EN
All parameters are specified at 24V, 3.8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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Germany
1/20
CD5.241-L1
DC/DC Converter 24V, 3.8A
CD-Series
INDEX
Page
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Intended Use .......................................................3
Installation Requirements...................................3
Input Voltage ......................................................4
Soft-start and Input Inrush Current Surge .........5
Output .................................................................6
Hold-up Time.......................................................7
Efficiency and Power Losses................................8
Functional Diagram.............................................9
Front Side and User Elements.............................9
Terminals and Wiring........................................10
Reliability ...........................................................10
EMC....................................................................11
Environment ......................................................12
Protection Features ...........................................12
Safety Features ..................................................13
Dielectric Strength ............................................13
Used Substances ................................................13
Page
18. Approvals .......................................................... 14
19. Fulfilled Standards............................................ 14
20. Physical Dimensions and Weight ..................... 15
21. Accessories ........................................................ 16
22. Application Notes............................................. 17
22.1. Peak Current Capability ...........................17
22.2. Back-feeding Loads ..................................17
22.3. Inductive and Capacitive Loads................17
22.4. External Input Protection.........................18
22.5. Requirements for the Supplying Source..18
22.6. Parallel Use to Increase Output Power....18
22.7. Parallel Use for Redundancy ....................18
22.8. Series Operation .......................................19
22.9. Charging of Batteries ...............................19
22.10. Use in a Tightly Sealed Enclosure ............19
22.11. Mounting Orientations ............................20
The information presented in this document is believed to be accurate and reliable and may change without notice.
Some parts of this unit are patent by PULS (US patent No 091662,063, Des. 424,529, …).
No part of this document may be reproduced or utilized in any form without permission in writing from PULS GmbH.
TERMINOLOGY AND ABREVIATIONS
PE and
symbol
PE is the abbreviation for Protective Earth and has the same meaning as the symbol
.
Earth, Ground
This document uses the term “earth” which is the same as the U.S. term “ground”.
T.b.d.
To be defined, value or description will follow later.
DC 24V
A figure displayed with the AC or DC before the value represents a nominal voltage with
standard tolerances included.
E.g.: DC 12V describes a 12V battery disregarding whether it is full (13.7V) or flat (10V)
24Vdc
A figure with the unit (Vac) at the end is a momentary figure without any additional
tolerances included.
Oct 2009 / Rev. 1.0 DS-CD5.241-L1-EN
All parameters are specified at 24V, 3.8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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Germany
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CD5.241-L1
DC/DC Converter 24V, 3.8A
CD-Series
1. INTENDED USE
This device is designed for installation in an enclosure and is intended for the general use such as in industrial control,
office, communication, and instrumentation equipment.
Do not use this DC/DC converter in aircrafts, trains and nuclear equipment where malfunction may cause severe
personal injury or threaten human life.
This device is designed for use in hazardous, non-hazardous, ordinary or unclassified locations.
2. INSTALLATION REQUIREMENTS
This device may only be installed and put into operation by qualified personnel.
This device does not contain serviceable parts. The tripping of an internal fuse (if included) is caused by an internal
defect.
If damage or malfunction should occur during installation or operation, immediately turn power off and send unit to
the factory for inspection.
Mount the unit on a DIN-rail so that the output terminals are located on top and input terminal on the bottom. For
other mounting orientations see de-rating requirements in this document.
This device is designed for convection cooling and does not require an external fan. Do not obstruct airflow and do
not cover ventilation grid (e.g. cable conduits) by more than 30%!
Keep the following installation clearances: 40mm on top, 20mm on the bottom, 5mm on the left and right sides are
recommended when the device is loaded permanently with more than 50% of the rated power. Increase this clearance
to 15mm in case the adjacent device is a heat source (e.g. another DC/DC converter).
WARNING
Risk of electrical shock, fire, personal injury or death.
- Do not use the DC/DC converter without proper grounding (Protective Earth). Use the terminal on the input block
for earth connection and not one of the screws on the housing.
- Turn power off before working on the device. Protect against inadvertent re-powering.
- Make sure that the wiring is correct by following all local and national codes.
- Do not modify or repair the unit.
- Do not open the unit as high voltages may present inside.
- Use caution to prevent any foreign objects from entering the housing.
- Do not use in wet locations or in areas where moisture or condensation can be expected.
- Do not touch during power-on, and immediately after power-off. Hot surface may cause burns.
Oct 2009 / Rev. 1.0 DS-CD5.241-L1-EN
All parameters are specified at 24V, 3.8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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Germany
3/20
CD5.241-L1
DC/DC Converter 24V, 3.8A
CD-Series
3. INPUT VOLTAGE
Input voltage
Input voltage range
nom.
DC 24V
14.4-32.4Vdc
36.0Vdc
max.
Allowed voltage between input
and earth
Allowed input ripple voltage
Turn-on voltage
Shut-down voltage
Input current
Start-up delay
Rise time
Turn-on overshoot
Input capacitance
max.
max.
60Vdc or
42.2Vac
5Vpp
typ.
typ.
typ.
typ.
typ.
typ.
typ.
max.
typ.
17.5Vdc
14.0Vdc
35.0Vdc
4.25A
290ms
520ms
610ms
500mV
3 000μF
full specified
absolute maximum continuous input voltage with no
damage to the DC/DC converter
in case the output voltage is not grounded.
47Hz-40kHz, the momentary input voltage must always
be within the specified limits.
steady-state value, see Fig. 3-1
steady-state value, see Fig. 3-1
steady-state value, see Fig. 3-1
at 24Vdc input and output 24V, 3.8A, see Fig. 3-3
see Fig. 3-2
0mF, 24V, resistive load 3.8A, see Fig. 3-2
3.8mF, 24V, resistive load 3.8A, see Fig. 3-2
see Fig. 3-1
external capacitors on the input voltage bus are allowed
without any limitations.
Fig. 3-1 Input voltage range
Rated input range
Turn-on
Shut-down
POUT
32.4Vdc
35.0Vdc
17.5Vdc
14.0Vdc
14.4Vdc
VIN
Fig. 3-2 Turn-on behavior, definitions
Input
Voltage
Fig. 3-3 Input current vs. output load
6A
Input Current, typ
dc
18V
:
t
u
Inp
c
4Vd
t: 2
u
p
In
5
4
- 5%
Start-up
delay
Rise
Time
Overshoot
3
Output
Voltage
2
1
Output Current
0
0.5
1
1.5
2
2.5
3
3.5
4A
Oct 2009 / Rev. 1.0 DS-CD5.241-L1-EN
All parameters are specified at 24V, 3.8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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CD5.241-L1
DC/DC Converter 24V, 3.8A
CD-Series
4. SOFT-START AND INPUT INRUSH CURRENT SURGE
Inrush current limitation
An active inrush limitation circuit (inrush limiting resistor which is bypassed by a relay contact) limits the input inrush
current after turn-on of the input voltage.
The charging current into EMI suppression capacitors is disregarded in the first microseconds after switch-on.
Inrush current
max.
typ.
typ.
Inrush energy
1.6Apeak
1.2Apeak
negligible
-25°C to +70°C, input: 24Vdc
-25°C to +70°C, input: 24Vdc
-25°C to +70°C, input: 24Vdc
Fig. 4-1 Input inrush current, typical behavior
Input Current
Input Voltage
Input:
Output:
Ambient:
24Vdc
24V, 3.8A, constant current load
25°C
Upper curve:
Middle curve:
Lower curve:
Time basis:
Input current 2A / DIV
Input voltage 20V / DIV
Output voltage 20V / DIV
100ms / DIV
Output Voltage
Soft-start function:
After the DC/DC converter is turned on, the internal output current rises slowly to its nominal value. This method
charges the output capacitors (internal and external capacitors) slowly and avoids high input currents during turn-on.
High input currents can produce a high voltage drop on the input wiring (especially with long and thin cables) which
reduces the terminal voltage on the DC/DC converter. If the terminal voltage is below the shut-down voltage, the
DC/DC converter will turn-off and will make a new start-up attempt. This effect is avoided with the integrated softstart function. Please note, that this function increases the rise time of the output voltage by a small amount.
Fig. 4-2 Soft-start behavior
Input Current
Input:
24Vdc
Output:
24V, 3.8A, constant current load
Ambient:
25°C
No additional external output capacitors
Upper curve:
Lower curve:
Time basis:
Input current 2A / DIV
Output voltage 10V / DIV
20ms / DIV
Output Voltage
Oct 2009 / Rev. 1.0 DS-CD5.241-L1-EN
All parameters are specified at 24V, 3.8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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CD5.241-L1
DC/DC Converter 24V, 3.8A
CD-Series
5. OUTPUT
Output voltage
Adjustment range
Factory setting
Line regulation
Load regulation
Ripple and noise voltage
Output current
Output power
Short-circuit current
nom.
min.
max.
max.
max.
nom.
nom.
min.
max.
typ.
Output capacitance
24V
24.1V
25mV
100mV
50mVpp
3.8A
92W
3A
6A
2 200μF
Fig. 5-1 Output voltage vs. output current,
typ.
Output Voltage
not adjustable
±0.2%, at full load, cold unit
Input voltage variations between 18 to 32.4Vdc
static value, 0A å 3.8A
20Hz to 20MHz, 50Ohm
see Fig. 5-1
continuous current, short circuit impedance 200mOhm
continuous current, short circuit impedance 200mOhm
Fig. 5-2 Current limitation vs. input voltage,
(23V constant voltage load), typ.
Output Current
28V
4.3A
24
4.2
20
4.1
16
4.0
12
3.9
8
3.8
4
0
Output Current
0
1
2
3
Input Voltage
3.7
4
5
6A
14 16 18 20 22 24 26 28 30 32Vdc
Peak current capability (up to several milliseconds)
The DC/DC converter can deliver a peak current, which is higher than the specified short term current. This helps to
start current demanding loads or to safely operate subsequent circuit breakers.
The extra current is supplied by the output capacitors inside the DC/DC converter. During this event, the capacitors will
be discharged and causes a voltage dip on the output. Detailed curves can be found in chapter 22.1.
Peak current voltage dips
typ.
typ.
typ.
from 24V to 16V
from 24V to 12.5V
from 24V to 8.5V
at 7.6A for 50ms, resistive load
at 15.2A for 2ms, resistive load
at 15.2A for 5ms, resistive load
Oct 2009 / Rev. 1.0 DS-CD5.241-L1-EN
All parameters are specified at 24V, 3.8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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CD5.241-L1
DC/DC Converter 24V, 3.8A
CD-Series
6. HOLD-UP TIME
The input side of the DC/DC converter is equipped with a bulk capacitor which keeps the output voltage alive for a
certain period of time when the input voltage dips or is removed. The bulk capacitor can be discharged by loading the
DC/DC converter on the output side or through a load which is parallel to the input. There is no protection in the
DC/DC converter which prevents current from flowing back to the input terminals. If prevention is needed, an external
diode should be used.
Hold-up Time
typ.
typ.
13.8ms
7ms
input 24Vdc, output: 24Vdc, 1.9A, see Fig. 6-1
input 24Vdc, output: 24Vdc, 3.8A, see Fig. 6-1
Fig. 6-1 Hold-up time vs. input voltage
Hold-up Time
12ms
10
(a)
(b)
8
(c)
(d)
6
4
(a) 24V, 1.9A, typ.
(b) 24V, 1.9A, min.
(c) 24V, 3.8A, typ.
(d) 24V, 3.8A, min.
2
Input Voltage
0
18
20
22
24
28Vdc
26
Fig. 6-2 Shut-down test setup
S1
+
DC
Source
-
DC/DC
Converter
Input
+
Intput
Voltage
S1 opens
+
CD5
Output -
Fig. 6-3 Shut-down behavior, definitions
Load
-
- 5%
Output
Voltage
Hold-up Time
Note: At no load, the hold-up time can be up to several seconds. The green DC-ok lamp is also on during this time.
Oct 2009 / Rev. 1.0 DS-CD5.241-L1-EN
All parameters are specified at 24V, 3.8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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CD5.241-L1
DC/DC Converter 24V, 3.8A
CD-Series
7. EFFICIENCY AND POWER LOSSES
Efficiency
Power losses
Fig. 7-1
Input 24Vdc
90.5%
0.7W
5.5W
9.7W
typ.
typ.
typ.
typ.
at 24V, 3.8A
at no output load
at 24V, 1.9A
at 24V, 3.8A
Fig. 7-2
Efficiency vs. output current at 24V,
typ.
Losses vs. output current at 24V,
typ.
Power Losses
Efficiency
91%
12W
90
10
89
8
88
6
87
4
2
86
Output Current
85
0.5
Fig. 7-3
1
1.5
2
2.5
3
Output Current
0
3.5
0
4A
Efficiency vs. input voltage at 24V,
3.8A, typ.
Fig. 7-4
2
3
4A
Losses vs. input voltage at 24V, 3.8A,
typ.
Efficiency
Power Losses
91%
12W
90.5
10
90.0
8
89.5
6
89.0
4
2
88.5
88.0
18
1
Input Voltage
20
22
24
26
Input Voltage
0
28
30 32Vdc
18
20
22
24
26
28
30 32Vdc
Oct 2009 / Rev. 1.0 DS-CD5.241-L1-EN
All parameters are specified at 24V, 3.8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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CD5.241-L1
DC/DC Converter 24V, 3.8A
CD-Series
8. FUNCTIONAL DIAGRAM
Fig. 8-1 Functional diagram
+
-
Input Fuse
&
Input Filter
Chassis
Ground
Reverse
Polarity
Protection
&
Inrush
Limiter
OverTemperature
Protection
Power
Converter
Output
Filter
Output
OverVoltage
Protection
+
+
DC
ok
9. FRONT SIDE AND USER ELEMENTS
Fig. 9-1 Front side
A
Input terminals
Screw terminals
+ Positive input
- Negative (return) input
Chassis ground: can be used to bond the housing to PE
Ground this terminal to minimize high-frequency emissions.
B
Output terminals
Screw terminals, dual terminals per pole, both pins are equal
+ Positive output
- Negative (return) output Screw terminals
C
DC-OK LED (green)
On when the voltage on the output terminals is > 21V
Oct 2009 / Rev. 1.0 DS-CD5.241-L1-EN
All parameters are specified at 24V, 3.8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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CD5.241-L1
DC/DC Converter 24V, 3.8A
CD-Series
10. TERMINALS AND WIRING
Type
Solid wire
Stranded wire
American Wire Gauge
Wire stripping length
Input
spring-clamp terminals
0.5-6mm2
0.5-4mm2
20-10 AWG
10mm / 0.4inch
Output
spring-clamp terminals
0.5-6mm2
0.5-4mm2
20-10 AWG
10mm / 0.4inch
Instructions:
a) The external circuitry of all terminals must meet the safety requirements stipulated by IEC/EN/UL 60950-1: SELV.
b) Use appropriate copper cables that are designed for an operating temperature of:
60°C for ambient up to 45°C and
75°C for ambient up to 60°C minimum
90°C for ambient up to 70°C minimum.
c) Follow national installation codes and installation regulations!
d) Ensure that all strands of a stranded wire enter the terminal connection!
e) Up to two stranded wires with the same cross section are permitted in one connection point.
f) Screws of unused terminal compartments should be securely tightened.
g) Ferrules are allowed, but not required
11. RELIABILITY
Lifetime expectancy *)
MTBF **) SN 29500, IEC 61709
MTBF **) MIL HDBK 217F
Input 24Vdc
228 000h
134 000h
378 000h
1 487 000h
2 534 000h
665 000h
937 000h
at 24V, 1.9A and 40°C
at 24V, 3.8A and 40°C
at 24V, 3.8A and 25°C
at 24V, 3.8A and 40°C
at 24V, 3.8A and 25°C
at 24V, 3.8A and 40°C; Ground Benign GB40
at 24V, 3.8A and 25°C; Ground Benign GB25
*)
The Lifetime expectancy shown in the table indicates the minimum operating hours (service life) and is determined by the lifetime
expectancy of the built-in electrolytic capacitors. Lifetime expectancy is specified in operational hours and is calculated according to the
capacitor’s manufacturer specification. The prediction model allows only a calculation of up to 15 years from date of shipment.
**) MTBF stands for Mean Time Between Failure, which is calculated according to statistical device failures, and indicates reliability of a
device. It is the statistical representation of the likelihood of a unit to fail and does not necessarily represent the life of a product.
The MTBF figure is a statistical representation of the likelihood of a device to fail. A MTBF figure of e.g. 1 000 000h means that
statistically one unit will fail every 100 hours if 10 000 units are installed in the field. However, it can not be determined if the failed unit
has been running for 50 000h or only for 100h.
Oct 2009 / Rev. 1.0 DS-CD5.241-L1-EN
All parameters are specified at 24V, 3.8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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CD5.241-L1
DC/DC Converter 24V, 3.8A
CD-Series
12. EMC
The DC/DC converter is suitable for applications in industrial environment as well as in residential, commercial and
light industry environment without any restrictions. The CE mark indicates conformance with EMC guideline
89/336/EEC, 93/68/EEC and 2004/108/EC and the low-voltage directive (LVD) 73/23/EWG and 2006/95/EC. A detailed EMC
report is available on request.
EMC Immunity
Electrostatic discharge
Electromagnetic RF field
Fast transients (Burst)
Surge voltage on input
Surge voltage on output
Conducted disturbance
Generic standards: EN 61000-6-1 and EN 61000-6-2
EN 61000-4-2
Contact discharge
Air discharge
EN 61000-4-3
80MHz-2.7GHz
EN 61000-4-4
Input lines
Output lines
EN 61000-4-5
+å+/- å chassis ground
EN 61000-4-5
+å+ / - å chassis ground
EN 61000-4-6
0.15-80MHz
8kV
15kV
10V/m
4kV
2kV
1kV
2kV
500V
500V
10V
Criterion A
Criterion A
Criterion A
Criterion A
Criterion A
Criterion A
Criterion A
Criterion A
Criterion A
Criterion A
Criterions:
A: DC/DC converter shows normal operation behavior within the defined limits.
C: Temporary loss of function is possible. DC/DC converter may shut-down and restarts by itself. No damage or hazards for the DC/DC
converter will occur.
EMC Emission
Conducted emission
Generic standards: EN 61000-6-3 and EN 61000-6-4
Class B, input lines
(Limits for DC power ports)
Class B
IEC/CISPR 16-1-2, IEC/CISPR 16-2-1
Radiated emission
EN 55011, EN 55022
This device complies with FCC Part 15 rules.
Operation is subjected to following two conditions: (1) this device may not cause harmful interference, and (2) this
device must accept any interference received, including interference that may cause undesired operation.
Switching frequency
Variable between 90kHz and 135kHz depending on load and input voltage
(output current > 0.5A)
Oct 2009 / Rev. 1.0 DS-CD5.241-L1-EN
All parameters are specified at 24V, 3.8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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CD5.241-L1
DC/DC Converter 24V, 3.8A
CD-Series
13. ENVIRONMENT
Operational temperature *)
Storage temperature
Humidity **)
Vibration sinusoidal
Shock
Altitude
Altitude de-rating
Over-voltage category
-25°C to +70°C (-13°F to 158°F)
-40 to +85°C (-40°F to 185°F)
5 to 95% r.H.
2-17.8Hz: ±1.6mm; 17.8-500Hz: 2g
2 hours / axis
30g 6ms, 20g 11ms
3 bumps / direction, 18 bumps in total
0 to 6000m (0 to 20 000ft)
see Fig. 13-1
for storage and transportation
IEC 60068-2-30
IEC 60068-2-6
IEC 60068-2-27
Reduce output power or ambient temperature
above 2000m sea level.
above 2000m (6500ft), see Fig. 13-2
IEC 62103, EN 50178, altitudes up to 2000m
Altitudes from 2000m to 6000m
IEC 62103, EN 50178, not conductive
5.8W/1000m or 5°C/1000m
III
II
2
Degree of pollution
*) Operational temperature is the same as the ambient temperature and is defined as the air temperature 2cm below the unit.
**) Do not energize while condensation is present
Fig. 13-1 Output current vs. ambient temp.
Fig. 13-2 Output current vs. altitude at 24V
Allowable Output
Current
Allowable Output
Current
4A
4A
3
3
2
2
1
B
A
A... Tamb < 70°C
B... Tamb < 60°C
1
Ambient Temperature
0
-25
0
20
40
Altitude
0
60 70°C
0
2000
4000
6000m
14. PROTECTION FEATURES
Output protection
Output over-voltage protection
Electronically protected against overload, no-load and short-circuits *)
typ. 31Vdc
in case of an internal power supply defect, a redundant
max. 32Vdc
circuit limits the maximum output voltage. The output
shuts down and automatically attempts to restart.
Reverse input polarity protection Included
unit does not start when input voltage is reversed
Output over-current protection
electronically limited *)
see Fig. 5-1
Degree of protection
IP 20
EN/IEC 60529
Penetration protection
> 3.5mm
e.g. screws, small parts
Over-temperature protection
yes
output shut-down with automatic restart
Input transient protection
MOV
Metal Oxide Varistor
Internal input fuse
T10A H.B.C.
not user replaceable
*)
In case of a protection event, audible noise may occur.
Oct 2009 / Rev. 1.0 DS-CD5.241-L1-EN
All parameters are specified at 24V, 3.8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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CD5.241-L1
DC/DC Converter 24V, 3.8A
CD-Series
15. SAFETY FEATURES
Input / output separation *)
SELV
PELV
III
IEC/EN 60950-1
IEC/EN 60204-1, EN 50178, IEC 62103, IEC 60364-4-41
PE (Protective Earth) connection not required. A
connection of the “Chassis Ground” pin to earth is
recommended for best EMI performance
> 5MOhm
input to output, 500Vdc
< 0.1Ohm
between housing and Chassis Ground terminal
The leakage current which is produced by the DC/DC converter itself depends on the
input voltage ripple and need to be investigated in the final application.
For a smooth DC input voltage, the produced leakage current is less than 100μA.
Class of protection
Isolation resistance
PE resistance
Touch current (leakage current)
*)
Double or reinforced insulation
16. DIELECTRIC STRENGTH
The output voltage is floating and has no ohmic connection to the ground.
Type and factory tests are conducted by the manufacturer. Field tests may be conducted in the field using the
appropriate test equipment which applies the voltage with a slow ramp (2s up and 2s down). Connect all phaseterminals together as well as all output poles before conducting the test. When testing, set the cut-off current settings
to the value in the table below.
Fig. 16-1 Dielectric strength
Type test
Input
+
B
-
60s
A
1500Vac
B
1500Vac
C
500Vac
Factory test
5s
1500Vac
1500Vac
500Vac
Field test
5s
1000Vac
1000Vac
500Vac
> 30mA
> 30mA
> 12mA
Cut-off current setting
Output
A
Chassis
ground
+
C
-
To fulfill the PELV requirements according to EN60204-1 § 6.4.1, we
recommend that either the + pole, the – pole or any other part of
the output circuit shall be connected to the protective earth
system. This helps to avoid situations in which a load starts
unexpectedly or can not be switched off when unnoticed earth
faults occur.
17. USED SUBSTANCES
The unit does not release any silicone and is suitable for the use in paint shops.
The unit conforms to the RoHS directive 2002/96/EC
Electrolytic capacitors included in this unit do not use electrolytes such as Quaternary Ammonium Salt Systems.
Plastic housings and other molded plastic materials are free of halogens, wires and cables are not PVC insulated.
The production material within our production does not include following toxic chemicals:
Polychlorized Biphenyl (PCB), Polychlorized Terphenyl (PCT), Pentachlorophenol (PCP), Polychlorinated naphthalene
(PCN), Polybrom Biphenyll (PBB), Polybrom Bipheny-oxyd (PBO), Polybrominated Diphenylether (PBDE), Polychlorinated
Diphenylether (PCDE), Polydibromphenyl Oxyd (PBDO), Cadmium, Asbest, Mercury, Silicia
Oct 2009 / Rev. 1.0 DS-CD5.241-L1-EN
All parameters are specified at 24V, 3.8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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13/20
CD5.241-L1
DC/DC Converter 24V, 3.8A
CD-Series
18. APPROVALS
IEC 60950-1
IEC 61010-1
UL 508
ANSI / ISA 12.12.01-2007
UL 60950-1
NEC Class 2
UL 61010-1
ANSI / ISA 12.12.01-2007
ATEX
CB Scheme,
Information Technology Equipment
CB Scheme,
Electrical Equipment for Measurement, Control and
Laboratory Use
LISTED for use as Industrial Control Equipment;
U.S.A. (UL 508) and Canada (C22.2 No. 107-1-01);
IND. CONT. EQ.
E-File: E198865
LISTED for use in Hazardous Location Class I Div 2 T4 Groups
A,B,C,D systems; U.S.A. (ANSI / ISA 12.12.01-2007) and Canada
IND. CONT. EQ.
(C22.2 No. 213-M1987); E-File: E327416
RECOGNIZED for the use as Information Technology
Equipment, Level 3; U.S.A. (UL 60950-1) and Canada (C22.2
No. 60950-1); E-File: E137006
According to NEC (National Electrical Code) Article 725-41 (4).
NEC CLASS 2
Listed as Limited Power Source (LPS) in the UL 60950-1 UL
report.
RECOGNIZED for use in Electrical Equipment for
Measurement, Control and Laboratory Use;
E-File: E326782
RECOGNIZED for use in Hazardous Location Class I Div 2 T4
Groups A,B,C,D systems; U.S.A. (ANSI / ISA 12.12.01-2007) and
Canada (C22.2 No. 213-M1987); E-File: E246877
The unit is suitable for use in Class I Division 2 Groups A, B, C, D locations.
Substitution of components may impair suitability for Class I Division 2 environment.
Do not disconnect equipment unless power has been switched off. Wiring must be
in accordance with Class I, Division 2 wiring methods of the National Electrical Code,
NFPA 70, and in accordance with other local or national codes.
Suitable for use in Class 1 Zone 2 Groups IIa, IIb and IIc
locations. Number of ATEX certificate: EPS 08 ATEX 1 142 X.
DC/DC converter must be built-in in an IP54 enclosure.
II 3G Ex nAC II T4
19. FULFILLED STANDARDS
EN 61558-2-17
EN/IEC 60204-1
EN/IEC 61131-2
EN 50178, IEC 62103
Safety of Power Transformers
Safety of Electrical Equipment of Machines
Programmable Controllers
Electronic Equipment in Power Installations
Oct 2009 / Rev. 1.0 DS-CD5.241-L1-EN
All parameters are specified at 24V, 3.8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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CD5.241-L1
CD-Series
DC/DC Converter 24V, 3.8A
20. PHYSICAL DIMENSIONS AND WEIGHT
Weight
DIN-Rail
Installation Clearances
425g / 0.94lb
Use 35mm DIN-rails according to EN 60715 or EN 50022 with a height of 7.5 or 15mm.
The DIN-rail height must be added to the unit depth (102mm) to calculate the total required
installation depth.
See chapter 2
Fig. 20-1 Front view
Fig. 20-2 Side view
Oct 2009 / Rev. 1.0 DS-CD5.241-L1-EN
All parameters are specified at 24V, 3.8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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Germany
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CD5.241-L1
DC/DC Converter 24V, 3.8A
CD-Series
21. ACCESSORIES
ZM1.WALL Wall mounting bracket
This bracket is used to mount specific Dimension units onto a flat surface without utilizing a DIN-Rail. The two
aluminum brackets and the black plastic slider of the unit have to be removed, so that the two steel brackets can be
mounted.
Fig. 21-1 ZM1.WALL Wall mounting bracket
*)
Fig. 21-2 Assembled wall mounting bracket *)
Picture of the DC/DC converter is for representation only
ZM11.SIDE Side mounting bracket
This bracket is used to mount Dimension units sideways with or without utilizing a DIN-Rail. The two aluminum
brackets and the black plastic slider of the unit have to be detached, so that the steel brackets can be mounted.
For sideway DIN-rail mounting, the removed aluminum brackets and the black plastic slider need to be mounted on
the steel bracket.
Fig. 21-3
ZM11.SIDE Side mounting bracket *)
*)
Fig. 21-4
Side mounting with DIN-rail brackets *)
Picture of the DC/DC converter is for representation only
Oct 2009 / Rev. 1.0 DS-CD5.241-L1-EN
All parameters are specified at 24V, 3.8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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CD5.241-L1
DC/DC Converter 24V, 3.8A
CD-Series
22. APPLICATION NOTES
22.1. PEAK CURRENT CAPABILITY
Solenoids, contactors and pneumatic modules often have a steady state coil and a pick-up coil. The inrush current
demand of the pick-up coil is several times higher than the steady-state current and usually exceeds the nominal
output current (including the PowerBoost). The same situation applies, when starting a capacitive load.
Branch circuits are often protected with circuit breakers or fuses. In case of a short or an overload in the branch circuit,
the fuse needs a certain amount of over-current to trip or to blow. The peak current capability ensures the safe
operation of subsequent circuit breakers.
Assuming the input voltage is turned on before such an event, the built-in large sized output capacitors inside the
DC/DC converter can deliver extra current. Discharging this capacitor causes a voltage dip on the output. The following
two examples show typical voltage dips:
Fig. 22-1 Peak loading with 2x the nominal
current for 50ms, typ.
Output
Voltage
24V
7.6A
Fig. 22-2 Peak loading with 5x the nominal
current for 5ms, typ.
24V
19A
16V
Output
Voltage
8.5V
Output
Current
0A
Output
Current
0A
10ms/DIV
1ms/DIV
Peak load 7.6A (resistive load) for 50ms
Output voltage dips from 24V to 16V.
Peak load 19A (resistive load) for 5ms
Output voltage dips from 24V to 8.5V.
22.2. BACK-FEEDING LOADS
Loads such as decelerating motors and inductors can feed voltage back to the DC/DC converter. This feature is also
called return voltage immunity or resistance against Back- E.M.F. (Electro Magnetic Force).
This DC/DC converter is resistant and does not show malfunctioning when a load feeds back voltage to the DC/DC
converter. It does not matter, whether the DC/DC converter is on or off.
The maximum allowed feed-back-voltage is 30Vdc. The absorbing energy can be calculated according to the built-in
large sized output capacitance which is specified in chapter 5.
22.3. INDUCTIVE AND CAPACITIVE LOADS
The unit is designed to supply any kind of loads, including unlimited capacitive and inductive loads.
Oct 2009 / Rev. 1.0 DS-CD5.241-L1-EN
All parameters are specified at 24V, 3.8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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CD5.241-L1
DC/DC Converter 24V, 3.8A
CD-Series
22.4. EXTERNAL INPUT PROTECTION
The unit is tested and approved for branch circuits up to 50A. An external protection is only required, if the supplying
branch has an ampacity greater than this. Check also local codes and local requirements. In some countries local
regulations might apply.
If an external fuse is necessary or utilized, minimum requirements need to be considered to avoid nuisance tripping of
the circuit breaker. A minimum value of 10A B- or 8A C-Characteristic breaker should be used.
22.5. REQUIREMENTS FOR THE SUPPLYING SOURCE
In certain circumstances, the input filter of the DC/DC converter can show a resonant effect which is caused by the
supplying network. Especially when additional external input filters are utilized, a superimposed AC voltage can be
generated on the input terminals of the DC/DC converter which might cause a malfunction of the unit. Therefore,
additional input filters are not recommended. To avoid the resonant effects, the minimal resistance of the supplying
network which depends on the inductance of the input network, shall be above the boundary curve in Fig. 22-3.
Fig. 22-3 External input filter requirements to
avoid filter instabilities
Resistance of the
supplying network
1 Ohm
(a)
(b)
100 mOhm
10 mOhm
(a) max.
(b) typ.
1 mOhm
0.1mH
1mH
10mH
Inductance of the supplying network
22.6. PARALLEL USE TO INCREASE OUTPUT POWER
This DC/DC-converter is designed to meet the NEC Class 2 requirements. Do not use in parallel to increase the output
current. This would increase the output current and violates the NEC Class 2 limitations. Use CD5.241 or CD5.241-S1.
22.7. PARALLEL USE FOR REDUNDANCY
This DC/DC-converter is designed to meet the NEC Class 2 requirements. Do not use in parallel for redundancy. This
would increase the output current and violates the NEC Class 2 limitations. Use CD5.241 or CD5.241-S1.
Oct 2009 / Rev. 1.0 DS-CD5.241-L1-EN
All parameters are specified at 24V, 3.8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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CD5.241-L1
CD-Series
DC/DC Converter 24V, 3.8A
22.8. SERIES OPERATION
This DC/DC-converter is designed to meet the NEC Class 2 requirements. Do not use in series to increase the output
voltage. This would increase the output power for the NEC Class 2 circuit and violates the NEC Class 2 limitations. Use
CD5.241 or CD5.241-S1.
22.9. CHARGING OF BATTERIES
This DC/DC converter can not be used to charge batteries. The output voltage is not adjustable.
22.10. USE IN A TIGHTLY SEALED ENCLOSURE
When the DC/DC converter is installed in a tightly sealed enclosure, the temperature inside the enclosure will be
higher than outside. In such situations, the inside temperature defines the ambient temperature for the DC/DC
converter.
The following measurement results can be used as a reference to estimate the temperature rise inside the enclosure.
The DC/DC converter is placed in the middle of the box, no other heat producing items are inside the box
Enclosure:
Load:
Input:
Temperature inside enclosure:
Temperature outside enclosure:
Temperature rise:
Rittal Typ IP66 Box PK 9516 100, plastic, 110x180x165mm
24V, 3A; (=80%) load is placed outside the box
24Vdc
37.7°C (in the middle of the right side of the DC/DC converter with a distance of 2cm)
22.2°C
15.5K
Oct 2009 / Rev. 1.0 DS-CD5.241-L1-EN
All parameters are specified at 24V, 3.8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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CD5.241-L1
DC/DC Converter 24V, 3.8A
CD-Series
22.11. MOUNTING ORIENTATIONS
Mounting orientations other than input terminals on the bottom and output on the top require a reduction in
continuous output power or a limitation in the max. allowed ambient temperature. The amount of reduction
influences the lifetime expectancy of the DC/DC converter. Therefore, two different derating curves for continuous
operation can be found below:
Curve A1
Curve A2
Recommended output current.
Max allowed output current (results in approximately half the lifetime expectancy of A1).
Fig. 22-4
Mounting
Orientation A
(Standard
orientation)
Output Current
OUTPUT
4A
A1
3
DC/DC
Converter
2
1
Ambient Temperature
0
INPUT
20
Fig. 22-5
Mounting
Orientation B
(Upside down)
50
70°C
60
INPUT
4A
A2
3
A1
DC/DC
Converter
2
Ambient Temperature
OUTPUT
0
20
Fig. 22-6
Mounting
Orientation C
(Table-top
mounting)
30
40
50
70°C
60
Output Current
4A
3
A2
2
A1
1
Ambient Temperature
0
20
30
40
50
70°C
60
Output Current
4A
OUTPUT
INPUT
DC/DC
Converter
A2
3
A1
2
1
Ambient Temperature
0
20
30
40
50
70°C
60
Output Current
INPUT
DC/DC
Converter
4A
OUTPUT
Fig. 22-8
Mounting
Orientation E
(Horizontal ccw)
40
Output Current
1
Fig. 22-7
Mounting
Orientation D
(Horizontal cw)
30
A2
3
A1
2
1
Ambient Temperature
0
20
30
40
50
60
70°C
Oct 2009 / Rev. 1.0 DS-CD5.241-L1-EN
All parameters are specified at 24V, 3.8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
www.pulspower.com Phone +49 89 9278 0
Germany
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